The Hydraulic Splitter Valve: Engineering Excellence

In Chinese hydraulic engineering terminology, what is commonly referred to as a multi-way valve typically belongs to the category of hydraulic splitter valve technology. The hydraulic splitter valve was developed primarily to meet the demanding requirements of mobile hydraulic systems, where a single pump must drive multiple hydraulic cylinders independently. This innovative design allows for precise control of multiple actuators while maintaining efficient fluid power distribution.

At its core, a hydraulic splitter valve consists of multiple control sections, where each section typically controls one (or a group of) hydraulic cylinders. These control sections share a common oil supply and return system, with the corresponding connection ports arranged on a supply section. This modular design is what gives the hydraulic splitter valve its versatility and efficiency in various applications.

The hydraulic splitter valve's construction revolves around its modular design, which allows for flexibility in configuration based on specific application requirements. The supply section, often referred to as the head section, is typically positioned on one side of the assembly. At the opposite end, a tail section is usually included, which primarily functions to seal the oil ports (see Figure 6-3 in technical references).

A key design feature of the hydraulic splitter valve is the uniform positioning of inlet and return ports across all sections. This standardization allows the various sections to be securely fastened together using bolts, creating a compact and integrated unit. This modular approach not only simplifies manufacturing but also facilitates maintenance and repair, as individual sections can be replaced if necessary.

Special Configurations

In configurations with a large number of control sections, engineers may position the supply section in the middle of the hydraulic splitter valve assembly to minimize pressure losses in the flow paths. In such cases, two tail sections are required to seal both ends of the assembly. Alternatively, some designs incorporate two supply sections, eliminating the need for tail sections entirely (as illustrated in Figure 6-3a of technical literature).

This flexibility in configuration demonstrates the adaptability of the hydraulic splitter valve to various system requirements, making it a versatile solution in mobile hydraulics. Whether configured with a single supply section at one end, a central supply section, or dual supply sections, the hydraulic splitter valve maintains its core advantage of efficient, independent control of multiple actuators from a single pump source.

The阀体 (valve body) of a hydraulic splitter valve is most commonly produced using casting techniques. This manufacturing method allows for the creation of complex, curved flow channels that minimize pressure losses within the hydraulic splitter valve (as shown in Figure 6-4). To ensure adequate pressure resistance and durability, high-grade ductile iron or vermicular graphite cast iron is typically employed.

Alternative Manufacturing Approaches

While casting is the predominant method, some manufacturers produce hydraulic splitter valve bodies from rolled steel blocks. The rolled steel offers a more homogeneous material structure, enabling the hydraulic splitter valve to withstand significantly higher pressures. However, this approach presents challenges in creating internal flow channels, which must be formed through drilling operations. These drilled passages typically consist of straight, intersecting channels that can result in greater pressure losses compared to the optimized curved paths possible with casting.

The choice between cast and steel block construction for a hydraulic splitter valve depends on the specific application requirements, particularly regarding operating pressure and flow efficiency. High-pressure applications may necessitate the steel block construction despite the potential for increased pressure losses, while applications prioritizing flow efficiency often favor the cast iron approach.

The hydraulic splitter valve has undergone significant functional evolution since its inception. Early designs of the hydraulic splitter valve possessed only directional control capabilities, allowing operators to control the movement direction of hydraulic cylinders.

A major advancement in hydraulic splitter valve technology came with the introduction of throttling grooves machined into the valve spools. This innovation transformed the basic directional valve into a directional throttle valve, enabling the hydraulic splitter valve to control not only the movement direction of hydraulic cylinders but also their speed through flow regulation. This dual functionality greatly expanded the applications and utility of the hydraulic splitter valve in various industrial and mobile hydraulic systems.

Safety and Protection Features

As hydraulic systems became more sophisticated, additional protective features were integrated into the hydraulic splitter valve design. To protect the pump, primary relief valves were incorporated into the supply section of the hydraulic splitter valve. These valves prevent system pressure from exceeding safe operating limits, safeguarding the pump and other system components.

To prevent overload damage to hydraulic cylinders, secondary relief valves were added to the control sections of the hydraulic splitter valve (as shown in Figure 6-5). These secondary valves provide individual protection for each actuator controlled by the hydraulic splitter valve, allowing for precise pressure settings tailored to the specific requirements of each cylinder or motor in the system.

Advanced Functional Enhancements

Further developments in hydraulic splitter valve technology addressed additional operational concerns. To prevent the creation of negative pressure (cavitation) in hydraulic cylinder chambers during operation, makeup valves were integrated into the hydraulic splitter valve design. These valves allow fluid to enter the cylinder chambers from a low-pressure source when necessary, preventing damage from cavitation.

In applications where a single pump (or group of pumps) supplies multiple hydraulic cylinders requiring simultaneous and independent movement, another significant advancement was made to the hydraulic splitter valve. To minimize flow competition and interference caused by load changes among the various actuators, pressure-compensating elements (pressure-compensated valves) were added to the hydraulic splitter valve design. These components, positioned upstream of the main control elements, maintain a constant pressure differential across the flow control orifices, ensuring consistent flow rates regardless of load variations.

This pressure-compensated design became known as the load-sensing hydraulic splitter valve (as illustrated in Figure 6-6). The load-sensing hydraulic splitter valve represents a sophisticated solution for complex mobile hydraulic systems, allowing for efficient operation of multiple actuators with varying loads while maintaining precise control and energy efficiency.

The incorporation of these advanced features has transformed the hydraulic splitter valve from a simple directional control device into a sophisticated, multi-functional component capable of precise control, system protection, and energy-efficient operation. Modern hydraulic splitter valve designs continue to evolve, incorporating electronic controls and smart features to meet the increasingly complex demands of modern mobile hydraulic systems.

The hydraulic splitter valve finds extensive application across a wide range of mobile and industrial hydraulic systems. Its ability to control multiple actuators from a single pump makes the hydraulic splitter valve particularly valuable in mobile equipment where space, weight, and efficiency are critical considerations.

In each of these applications, the hydraulic splitter valve provides reliable, precise control over multiple functions while maintaining system efficiency. The modular nature of the hydraulic splitter valve allows equipment designers to customize the number and type of control sections to match specific application requirements, from simple two-function systems to complex machines with dozens of hydraulic functions.

Modern hydraulic splitter valve designs, particularly those incorporating load-sensing technology, offer significant energy savings compared to older designs. By precisely matching flow and pressure to the demands of each actuator, the hydraulic splitter valve reduces unnecessary energy consumption, resulting in lower fuel usage in mobile equipment and reduced power requirements in industrial applications.

The hydraulic splitter valve represents a cornerstone of modern hydraulic system design, offering a versatile, efficient solution for controlling multiple actuators from a single power source. From its humble beginnings as a simple directional control device, the hydraulic splitter valve has evolved into a sophisticated component incorporating features such as flow control, pressure regulation, cavitation protection, and load sensing.

The modular construction of the hydraulic splitter valve, with its standardized porting and bolt-together design, provides equipment manufacturers with unparalleled flexibility in system design. Whether utilizing cast iron bodies with optimized flow paths or high-pressure steel block constructions, the hydraulic splitter valve continues to adapt to the evolving needs of mobile and industrial hydraulic applications.

As hydraulic systems continue to advance, the hydraulic splitter valve will undoubtedly play a central role in enabling more efficient, precise, and versatile hydraulic machinery. Its combination of functionality, reliability, and adaptability ensures that the hydraulic splitter valve will remain a critical component in hydraulic systems for years to come.